Molybdenum-silicon-boron alloy and method for producing same, and component

ABSTRACT

The use of a specific molybdenum-silicon-boron alloy and a particular production process in which powder is used makes it possible to achieve components which have a particular fiber-matrix structure and can be used for high-temperature applications and can also be produced inexpensively.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is the US National Stage of International Application No. PCT/EP2016/059342 filed Apr. 27, 2016, and claims the benefit thereof. The International Application claims the benefit of German Application No. DE 102015209583.5 filed May 26, 2015. All of the applications are incorporated by reference herein in their entirety.

FIELD OF INVENTION

The invention relates to a specific molybdenum-silicon-boron alloy, a production process and a component.

BACKGROUND OF INVENTION

Mo-(x)Si-(y)B alloys represent a potential opportunity for making hot gas components for a gas turbine which go beyond the use window of classical nickel-based superalloys. These alloys offer a use window up to a hot gas temperature of 1973K, with a coating up to 2073K. Widening of the use range by up to 300K, associated with a corresponding increase in the efficiency, compared to alloys used hitherto is thus possible.

The processing of these alloys can be carried out by a powder-metallurgical route, or else by means of zone melting. Zone melting leads, because of the temperature gradient which arises, to formation of a fiber-matrix structure which is impressive due to its excellent creep properties at temperatures above 1273K.

However, both processes allow only formation of simple test specimens, so that the potential of these alloys cannot be exploited at present.

SUMMARY OF INVENTION

It is therefore an object of the invention to solve the abovementioned problem.

The object is achieved by an alloy, a process and a component as claimed.

It is proposed that a novel Mo—Si—B alloy be processed by means of an additive manufacturing (AM) process such as Selective Laser Melting (SLM). Furthermore, the processing by means of an energy beam, for example a laser beam, in conjunction with the outward heat conduction conditions in the powder bed allows the formation of a temperature conduction gradient which in turn is advantageous for the optionally desired formation of a fiber-matrix structure in which the individual phases are present as Mo_(ss)/Mo₅SiB₂/Mo₃Si structure.

An optional alloying-in of zirconium (Zr) (0.5 at %-2 at %) leads to an advantageous increase in the fracture toughness of the alloy or of the component.

Furthermore, the AM process offers, compared to the powder-metallurgical process, the advantage that oxygen is very largely kept away from the workpiece. This has a positive effect on the materials properties.

DETAILED DESCRIPTION OF INVENTION

The process data for production by means of the AM process are advantageously:

-   -   Alloy: Mo-(x)Si-(y)B,     -   where x=3-19 at % and y=1-13 at %,     -   preferably x=13-18 at % and y=8-12 at %,     -   optional addition of zirconium (Zr) z=0.5 at %-2 at %,     -   preferably z=1 at %,     -   Particle size: 10-60 μm, either gas-atomized or milled,     -   as possible processing window:     -   Scanning speed: 400 mm/s-2000 mm/s,     -   preferably 1000 mm/s-1500 mm/s,     -   Laser power: 80 W-250 W,     -   preferably 100-170 W. 

1.-4. (canceled)
 5. An alloy comprising a composition Mo-(x)Si-(y)B-(z)Zr, wherein: x=13 at % to 19 at %, y=1 at % to 13 at %, and z=0.5 at % to 2 at %.
 6. The alloy as claimed in claim 5, wherein: x=13 at % to 18 at %, y=8 at % to 12 at %, and z=0.5 at % to 2 at %.
 7. The alloy as claimed in claim 5, consisting essentially of Mo, Si, B and Zr and formed by a selective laser melting process effective to form a fiber-matrix structure.
 8. A process for producing a component composed of the alloy of claim 5, the process comprising applying powder comprising Mo, Si, B and Zr with a selective energy beam melting process.
 9. The process as claimed in claim 8, wherein at least 80%, of particles of the powder have respective sizes in a range from 10 μm to 60 μm.
 10. The process as claimed in claim 8, wherein the powder has been gas-atomized or milled.
 11. The process as claimed in claim 8, wherein the selective energy beam melting process is controlled to achieve a temperature gradient effective to form a fiber-matrix structure.
 12. The process of claim 11, further comprising controlling the selective energy beam melting process to achieve a temperature gradient effective to form the fiber-matrix structure in which individual phases are present as Mo_(ss)/Mo₅SiB₂/Mo₃Si.
 13. The process of claim 11, wherein a scanning speed between the powder and a laser energy beam is between 400 mm/s and 2000 mm/s.
 14. The process of claim 13, wherein the scanning speed is between 1000 mm/s and 1500 mm/s.
 15. The process of claim 11, wherein the selective energy beam melting process utilizes a laser energy beam power of from 80 W to 250 W.
 16. The process of claim 15, wherein the selective energy beam melting process utilizes a laser beam power of from 100 W to 170 W.
 17. A component comprising the alloy as claimed in claim
 5. 18. A component formed by the process of claim
 11. 19. A component formed by the process of claim
 12. 20. A process for producing a component, the process comprising: melting powder comprising Mo, Si and B in a selective energy beam melting process; and controlling the melting and a subsequent cooling of the melted powder to achieve a temperature gradient effective to form a fiber-matrix structure.
 21. The process of claim 20, further comprising controlling the melting and subsequent cooling to achieve a temperature gradient effective to form the fiber-matrix structure in which individual phases are present as Mo_(ss)/Mo₅SiB₂/Mo₃Si.
 22. The process of claim 20, further comprising melting powder comprising Mo, Si, B and Zr.
 23. The process of claim 20, wherein the selective energy beam melting process comprises a selective laser melting process comprising: a laser beam power in a range of 80 W to 250 W; and a laser scanning speed in a range of 400 mm/s and 2000 mm/s.
 24. The process of claim 20, wherein the selective energy beam melting process is effective to keep oxygen away from the powder during formation of the fiber-matrix structure. 